Very nice grills ! Could we get more detail on how they are made as I have never made grills. Where is the material from?
Yup, the grills are pretty easy to make actually, I just don't like doing the cloth stage
To start I just used 1/2" MDF . Because I wanted 1/2" smaller than the baffle all the way around, I cut 2 pieces 48.5 x 7" . Once the blanks are cut, I layout the magnet positions on the frames ( I used N52 1/4" x 3/8" magnets). Once I have the positions marked, I drill small pilot holes for each. I then clamp the blank to the front baffle and position it correctly before drilling the holes throught the blank into the baffle. You can do it by measuring them out on the baffle as well, but with my lijmited vision, there is less chance of me making mistakes Then roud the outside edges with a 3/8" radius bit
Next I just laid out the center points for all the holes exactly the same as the front baffle - 1/2" to make up for the shorter lenght the grill s will be.. Next I drilled all the center points with a 1/8" bit for the circle jig . Before cutting out the circles, counter sunk the rear of all the woofer holes 1/4" deep to a diameter of 6.375. After all lthe woofer holes are coutersunk, you can cut out the thru holes to 5.5"
Now I clamped the frames to some scrap MDF. I then took a long piece of MDF and clamped it to the frame in such a way that it would act as a quide for a flush trim bit to cut out the pieces between the woofer holes You could leave a "bridge" between #2 and #3 lower woofers if you wanted but I didn't think it was neccessary so I cut them out to have one large opening for the lower section.
I just rounded all the inner edges of the cut outs with a piece of course andpaper as there isn't a whole lot of material left after the countersinks on the rear of all the woofer holes to use a router bit.
You can then drill out the magnet pilot holes to the right diameter and depth for the magnets. When I epoxy the magnets in, I revers the polarity on the 2 grills and speakers so that each grill only attacheds to the speker it was laid out on. After the epoxy is dry, just fill the little pilot holes behind the magnets and sand smooth You can then paint the frames
Finally wrap em in cloth and that is it. I used cloth from CSS (creative Sound Solutions ) . I think it is the same stuff that PE sells. It is a very open weave and is supposed to be acoustically transparent. Most of my listening will be done "grill less " anyhow.
-jay
